Preparation Part Number: Mounting Kit PT546-4700 Tuner Assy 8680-0W03 NOTE: Part number of this accessory may not be the same as the part number shown. Tuner Assembly Kit Contents (8680-0W03) Item # Quantity Reqd. Description Tuner Assy, Stereo Component Mounting Kit Contents (PT546-4700) Item # Quantity Reqd. Description Wire, To Radio Installation Antenna Cable 3 Ground Cable 4 Tuner Bracket 5 Base Bracket 6 Template (to locate base bracket) 7 4 Cushion (Butyl) 8 Hardware Bags 9 XM Satellite Radio Brochure Hardware Bag Contents (PT546-4700) Item # Quantity Reqd. Description 4 Bolt (M5 L8) 4 Nut (M6) Hardware Bag Contents (PT546-4700) Item # Quantity Reqd. Description 5 Lock Tie Cushion Tape (00 x 50 mm) 3 Sheet Tape (30 x 30 mm) 4 Protective Sheet (5 x 0 mm) 5 Protective Sheet (5 x 30 mm) 6 Protective Sheet (0 x 40 mm) 7 Protective Sheet (0 x 60 mm) 8 Protective Sheet (30 x 30 mm) Additional Items Required For Installation Item # Quantity Reqd. Description Satellite Receiver Cover P/N PT8-507 Conflicts Sirius, ipod Interface, Audio with embedded XM such as Tech Pkg, JBL & NAV Requirements XM satellite ready base grade audio Recommended Tools Personal & Vehicle Protection Safety Goggles Seat Covers Floor Protectors Special Tools Notes Notes Installation Tools Notes Ratchet Extensions Sockets 0 mm, mm, 4 mm Torque Wrench 5.4 N m (48 lbf in): Battery Cable, 37 N m (7 lbf ft): Front Seat Screwdriver Phillips, # Panel Removal Tool e.g. Panel Pry Tool # Masking Tape Utility Knife Special Chemicals Cleaner General Applicability Toyota SST # 0000-0600-0 ( wide) Notes VDC approved cleaner. Recommended Sequence of Application Item # Accessory VIP, Audio *Mandatory Vehicle Service Parts (may be required for reassembly) Item # Quantity Reqd. Description Legend STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue. SAFETY TORQUE: This mark indicates that torque is related to safety. Page of 4 pages
TOYOTA PRIUS 00- XM SATELLITE RADIO Preparation Parts Description of Receiver Assembly Radio Unit (8680-0W03) Item # Parts Name Parts No. Qty Tuner Assy, Stereo Component* 8680-0W03 * : In the installation instructions and figures, this is referred to as Tuner. Parts Description of Mounting Kit (PT546-4700) 3 4 5 6 7 8 9 0 3 A B C D E Item # Parts Name Qty Wire, To Radio Installation* Antenna Cable 3 Ground Cable 4 Tuner Bracket 5 Base Bracket 6 Template (to locate base brackets) 7 Cushion (Butyl) 4 8 Lock Tie 5 9 Bolt (M5 L8) 4 0 Nut (M6) 4 Cushion Tape (00 50 mm) Sheet Tape (30 x 30 mm) A (5 x 0 mm) B (5 x 30 mm) 3 C Protective Sheet (0 x 40 mm) D (0 x 60 mm) E (30 x 30 mm) * : In the installation instructions and figures, this is referred to as Tuner Cable. Page of 4 pages
Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:- Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). Safety (eye protection, rechecking torque procedure, etc.). Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. NOTES Removed Parts: - Place all removed parts on a protected surface. Connectors: - When disconnecting connectors, do not pull on the wires; pull on the connectors. Lock Ties: - When using lock ties to secure harness, clip the lock ties after securing them. Machine Screws: - Start all machine screws by hand. When disconnecting a yellow connector for the SRS airbag, wait 90 seconds or more after disconnecting the negative battery cable before performing the next task. Lock Knobs (x) No. Floor Board. Disassembly of Vehicle. (Luggage Area) (a) Remove the rear No. floor board as follows. (Fig. -) () Before starting cover the rear trunk edge and bumper with a blanket. Unlock Fig. - Lock Unlock () Rotate the lock knobs to the unlock position. (3) Remove the rear No. floor board. Page 3 of 4 pages
(b) Remove the rear deck floor box. (Fig. -) Fig. - Deck Floor Box (c) Remove the rear No.3 floor board. (Fig. -3) No.3 Floor Board Fig. -3 0 mm Socket, Ratchet Negative Battery Cable (d) Remove the negative battery cable of the auxiliary battery. (Fig. -4) () Do not touch the positive terminal with any tool when removing the cable. Battery Fig. -4 Nylon Made Panel Removal Tool. Disassembly of Vehicle. (Front Seat Area) (a) Remove the front left side door scuff plate. (Fig. -) Claws (x4) Front Door Scuff Plate () Disengage the ten (0) claws, then remove the front left side door scuff plate in the direction of arrows. Fig. - Claws (x6) Page 4 of 4 pages
Fig. - Nylon Made Panel Removal Tool Clips (x) Plastic Nut (x) Cowl Side Trim Board (b) Remove the left side cowl side trim board. (Fig. -) () Remove the one () plastic nut. () Disengage the two () clips, then remove the left side cowl side trim board. Nylon Made Panel Removal Tool Rear Door Scuff Plate (c) Remove the rear left side door scuff plate. (Fig. -3) () Disengage the seven (7) claws, then remove the rear left side door scuff plate in the direction of arrows. Fig. -3 Claws (x7) Nylon Made Panel Removal Tool, 4 mm Socket, Ratchet (d) Remove front left side seat. () Slide the left side seat forward. Seat Track Bracket Cover Fig. -4 Bolts (x) Claws (x4) 3 Seat Track Bracket Cover () Disengage the four (4) claws, and then remove the seat track bracket rear covers in the direction of the arrows. (Fig. -4) (3) Remove the two () bolts on the rear side. (Fig. -4) 4 mm Socket, Ratchet (4) Slide the driver seat rearward. (5) Remove the two () bolts on the front side. (Fig. -5) Bolts (x) Fig. -5 Page 5 of 4 pages
Panel Removal Tool (e) Remove the seat harness clamp. (Fig. -6) Fig. -6 Drivers Seat Clamp CAUTION: Be careful not to damage the harness clamp by forcibly removing it. (f) Tilt the front drivers seat back against the rear seat. Wrap the rear drivers side seat belt around the front drivers side seat headrest to hold the seat in place. (Fig. -7) CAUTION: Be careful not to damage the seat or other vehicle parts when moving the driver seat. Rear Belt Seat Fig. -7 Blanket for protection Nylon Made Panel Removal Tool Claws (x) Weather Strip Claws (x) Weather Strip (g) Remove the left side center pillar lower garnish. (Fig. -8) () Remove the left side front door opening trim weather strip from the left side center pillar. Center Pillar Lower Garnish Fig. -8 Nylon Made Panel Removal Tool, 0 mm Socket, Extension, Ratchet Claws (x3) Bolt (x) Clips (x) Cover () Remove the left side rear door opening trim weather strip. (3) Disengage the two () clips and four (4) claws, then remove the left side center pillar lower garnish in the direction of the arrows. (h) Remove the rear console box. (Fig. -9) () Disengage the three (3) claws and remove the cover. () Remove the one () bolt. Fig. -9 Page 6 of 4 pages
0 mm Socket, Extension, Ratchet (3) Remove the one () felt cover. (4) Remove the four (4) bolts. (Fig. -0) Fig. -0 Bolts (x4) Console Box Claws (x4) Nylon Made Panel Removal Tool (5) Disengage the eight (8) claws and disconnect the electrical connector, then remove the rear console box in the direction of the arrow. (Fig. -) Claws (x4) Fig. - Connector Console Box Center console area (30 x 30 mm) Protective Sheet (5 x 0 mm) (5 x 30 mm) (5 x 30 mm) (5 x 0 mm) Fig. 3- Front (0 x 60 mm) (0 x 40 mm) 3. Route the Tuner Cable and Antenna Cable. (a) Apply seven (7) protective sheets (5 x 0 mm, 5 x 30 mm, 5 x 0 mm, 5 x 30 mm, 0 x 40 mm, 0 x 60 mm, 30 x 30 mm) to the lower area of the rear console box as shown. (Fig. 3-) 0 mm Socket, Ratchet, Extension Existing Bolt (b) Install the ground cable. (Fig. 3-) () Loosen the existing bolt located on the lower area of the rear console box, and install the end of the tuner ground cable onto the bolt. Ground Cable Fig. 3- Page 7 of 4 pages
Tuner Cable Connector (c) Install the tuner cable connector and antenna cable connector to the vehicle wire harness connectors as shown in the figure. (Fig. 3-3) Vehicle Wire Harness Connectors Fig. 3-3 Antenna Cable Connector (d) Route the tuner cable, antenna cable and ground cable as shown, and then secure them with the one () cushion tape and one () lock tie. (Fig. 3-4) (e) Use the side cutter to cut off the excess lock tie length. 30 mm (9.05 in) 30 mm (5. in) 00 mm (3.94 in) (A) (B) (f) Mark each of the cables as shown in the figure. (Fig. 3-5) (A) Tuner cable: 30 mm (9.05 in) (B) Ground cable: 30 mm (5. in) (C) Antenna cable: 00 mm (3.94 in) Fig. 3-5 (C) Front Fig. 3-6 Side Cutter Marked Areas Lock Tie (x) Lock Tie (x) Tuner, Antenna and Ground Cable (g) Tie and secure the cables using one () lock tie at the point where the three cables join. (Fig. 3-6) (h) Secure the marked areas of the tuner cable, antenna cable and ground cable to the wire harness with the one () lock tie. (Fig. 3-6) (i) Use the side cutter to cut off the excess lock ties length. Page 8 of 4 pages
Side Cutter Tuner, Antenna and Ground Cable (j) Even out the length of the cables and secure the tuner cable, antenna cable and ground cable with the two () lock ties. (Fig. 3-7) Front (k) Use the side cutter to cut off the excess lock ties length. Fig. 3-7 Lock Ties (x) Left 0 mm Socket, Ratchet, Extension Bolt (x) Left Front 4. Install the Tuner. (a) Remove the fuel lid lock open lever assembly. (Fig. 4-) () Remove the one () bolt. Fuel Lid Lock Open Lever Assembly Fig. 4- () Remove the fuel lid lock open lever assembly in the direction of the arrows. Nylon Made Panel Removal Tool (b) Peel back the floor carpet and felt. (Fig.4-) Left Front () Disengage the three (3) clips for the floor carpet. Clips (x3) Fig. 4- Cushions (x4) (c) Install four (4) cushions (butyl) onto the bottom of base brackets. (Fig. 4-3) NOTE: Clean the base brackets and base bracket mounting area (using a VDC approved cleaner). Fig. 4-3 Base Base Brackets Page 9 of 4 pages
Left Corner of Floor Front Fig. 4-4 Seat Wire Harness Tuner, Antenna and Ground Cable Template (d) Push the bracket bolts through the backside of the template, and apply the template to the brackets. (e) Place the edge of the template attached to the brackets to the corner of the floor. (Fig. 4-4) (f) Apply pressure on the base brackets from above. (g) Detach the template from the brackets. (h) Place the floor carpet to the original position. (i) Route the tuner cable, antenna cable, ground cable, and seat wire harness through the floor carpet hole, and then reinstall the floor carpet. (Fig. 4-5) Fig. 4-5 Utility Knife Base Bracket Studs Positions ( 4) Fig. 4-6 (j) Verify the base bracket studs positions. Transfer each stud location onto the floor carpet using a utility knife to cut the four (4) holes in floor carpet. (Fig. 4-6) (k) Pass the base bracket studs through the carpet. Phillips Screwdriver Bolts ( ) Tuner Ground Cable (l) Install the tuner brackets and ground cable onto the tuner so the connectors face toward the forward of the vehicle. (Fig. 4-7) Bolts ( ) Fig. 4-7 Tuner Brackets ( ) Page 0 of 4 pages
0 mm Socket, Ratchet, Extension (m) Secure the tuner onto the base brackets. (Fig. 4-8) Nuts ( ) Nuts ( ) Tuner Fig. 4-8 Tuner Cable Antenna Cable (n) Plug the tuner cable and antenna cable into the tuner. (Fig. 4-9) () Connect the antenna cable connector to the tuner. () Connect the tuner cable connector to the tuner. Fig. 4-9 5. In Process Functional Test. (a) Temporarily reconnect negative battery cable. (b) Temporarily install the dome fuse. (c) Press the engine switch to "ACC" position. (d) Press the power button on the receiver/player head unit. (e) Press and release the "SAT" button on the head unit. () Verify that a satellite channel is received, or a "NO SIGNAL" message appears on the display. NOTE: If "ANTENNA" appears (flashing) on the display - then the antenna cable is disconnected from the satellite tuner. NOTE: If the head unit will not tune or go into satellite mode - then the tuner cable is disconnected from the satellite tuner. (f) Disconnect negative battery cable. Page of 4 pages
6. Installing Receiver Cover. (a) Remove the satellite receiver cover (P/N PT8-507) from the poly bag. (b) Shape the cover so that it forms an open box shape with the Velcro TM facing down. Fig.6- Velcro Backing Satellite Receiver Cover NOTE: Shipping and storage may have caused the shape to distort. (c) Peel the backing off the sewn-in Velcro TM strip inside the cover. (Fig. 6-). () Do not separate the Velcro TM. (d) Clean the top of satellite receiver box with a VDC approved cleaner. (e) Align the rear edge of the cover with the rear edge of the satellite receiver. (Fig. 6-). Fig.6- Rear Edge (f) Center cover to ensure satellite receiver mounting bolts are covered. Press Velcro TM to the floor carpet around the perimeter. (g) Press the sewn-in Velcro TM tab on the top underside of the cover firmly to the satellite receiver. (Fig. 6-3). Fig.6-3 Sewn-in Velcro TM Tab Page of 4 pages
4 mm Socket, Torque Wrench 7. Complete the Reassembly of Vehicle. (a) Reinstall the front left side seat. (Fig. 7-, 7-) Fig. 7- Bolts (x) Seat Track Bracket Covers (x) () Reconnect the seat electrical connectors. () Reinstall the four (4) bolts loosely, and then tighten to specified torque. (3) Tighten bolts to 37 N m (7 lbf ft). 4 mm Socket, Torque Wrench (b) Reconnect any disconnected electrical connector. (c) Verify the panels fit together properly with no uneven gaps between them. Fig. 7- Bolts (x) (d) Clean up and remove any trash. (e) Place the owner XM Satellite Radio brochure in the glove box. Fig. 8-0 mm Socket, Torque Wrench Battery Negative Battery Cable 8. Reconnect Negative Battery Cable. (a) Reconnect the vehicle s negative battery cable. (Fig. 8-) () Rotate the negative terminal from the original factory position to allow bolt to be tightened to the proper torque value. () Tighten the nut to 5.4 N m (48 lbf in). (3) Do not touch the positive terminal with any tool when installing the negative battery cable. (4) Install the No.3 floor board, rear deck floor box and No. floor board in position. Page 3 of 4 pages
TOYOTA PRIUS 009 - XM SATELLITE RADIO Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Satellite Radio Tuner *Verify the proper operation of the satellite radio tuner. Receiver/player Assembly *Verify the proper operation of the receiver/player assembly. *(Refer to the receiver assembly and radio owner's manuals.) Vehicle Function Checks Driver s seat belt reminder light Removed seat Verify the proper operation of the driver s seat belt reminder light. Verify the removed seat is securely fastened. Proper operations of the removed seat lock mechanism Verify the proper operation of the removed seat lock mechanism. SRS warning light Verify the proper operation of the SRS warning light. AUX socket Verify the proper operation of the AUX socket functions in the rear console box. Power point socket Fuel door release lever Verify the proper operation of the Power point socket functions in the rear console box. Verify the proper operation of the fuel door release lever and fuel door. Page 4 of 4 pages